Note: Descriptions are shown in the official language in which they were submitted.
THERMAL INSULATING CONSTRUCTION WRAP AND
METHODS FOR SAME
CLAIM OF PRIORITY
This patent application claims the benefit of priority of Gonzales et. al.,
U.S.
Provisional Patent Application Serial Number 62/502,397 entitled "THERMAL
INSULATING CONSTRUCTION WRAP AND METHODS FOR SAME" filed on
May 05, 2017 (Attorney Docket No. 3458.044PRV) which is hereby incorporated
by reference herein in its entirety.
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material that is
subject to copyright protection. The copyright owner has no objection to the
facsimile reproduction by anyone of the patent document or the patent
disclosure, as
it appears in the Patent and Trademark Office patent files or records, but
otherwise
reserves all copyright rights whatsoever. The following notice applies to the
software and data as described below and in the drawings that form a part of
this
document: Copyright R.H. Tamlyn & Sons, LP; Stafford, Texas, USA. All Rights
Reserved.
TECHNICAL FIELD
This document pertains generally, but not by way of limitation, to
construction wraps applied as barriers to buildings.
BACKGROUND
When constructing buildings (e.g., homes, offices or the like) a moisture
barrier is, in some examples, used on the exterior of the building. For
instance, a
house or construction wrap (herein a construction wrap) is applied over the
plywood
or other exterior material of the building. The construction wrap encloses
plywood,
framing, insulation and other components of the building and minimizes water
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intrusion. External fascia, such as brick, stone, siding, stucco or the like,
are applied
over the construction wrap to provide a decorative exterior to the building.
Water
intrusion through the external fascia is intercepted by the construction wrap
and
diverted away from the covered components of the building.
Construction wrap, in some examples includes a pliable polymer that is
wrapped around the features of the building including, but not limited to,
walls,
corners, fenestration openings (openings for .doors or window), vent openings
or the
like. One example of a construction wrap is Tamlyn Wrap, a registered
trademark
of R.H. Tamlyn 8z Sons, LP.
OVERVIEW
The present inventors have recognized, among other things, that a problem
to be solved can include increasing the heating and cooling efficiency of a
building.
In some examples, the framing of a building is constructed in a consistent,
often
building code mandated, manner. The building frame is covered with an exterior
sheathing such as plywood, and is then filled with insulation (e.g.,
fiberglass
insulation whether rolled or blown). Increasing the thermal resistance of the
building (e.g., an overall R-value) requires one or more of the use of better
and more
expensive grades of insulation, the use of thicker insulation with framing
having
greater depth (and corresponding expense and labor) or both. Each of these
options
require, in some examples, one or more of additional labor, premium materials
or
the like.
In other examples, for instance with piping, utility housings or the like,
aerogel boards and blankets are installed and provide insulation. An aerogel
is a
porous material derived from a gel wherein the liquid component of the gel is
replaced with a gas. The aerogel is a solid having extremely low density and
low
thermal conductivity (and conversely a high thermal resistance or R-value).
The
aerogel is applied as a planar sheet or board, or with gentle (large radius)
bends to
minimize fracture of the aerogel. Sharp corners and bends precipitate
fractures in
the aerogel and in some examples expose at least portions of the underlying
piping,
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housing or the like to environmental conditions including extremes of heat and
cold.
The thermal insulating properties of the aerogel are thereby reduced or
obviated.
The present subject matter provides a solution to these problems, such as by
a thermal insulating construction wrap that includes an aerogel insulating
layer
coupled with a pliable substrate film. The aerogel insulating layer includes
an
aerogel having a high thermal resistance. The aerogel insulating layer is
bonded to
a pliable substrate film that minimizes (e.g., minimizes or eliminates) water
intrusion through the film. Further, the pliable substrate film facilitates
the
wrapping of the construction wrap including the aerogel insulating layer
around
nearly any component including sharp corners, bends or the like commonly found
when wrapping a building with construction wrap. For instance, the aerogel
insulating layer is relatively brittle and as the construction wrap is folded
around
corners, into fenestration openings or the like the pliable substrate film
retains the
aerogel along the film and accordingly minimizes fractures or breaks in the
insulation otherwise found with sharply folded aerogel blankets or boards.
Further,
even with breaking of the aerogel (e.g., with wrapping, folding, creasing or
the like)
the aerogel insulating layer is retained along the pliable substrate film to
minimize
gaps and localize fractures at corners, bends or the like. In other examples,
the
aerogel insulation layer is constructed with flexible aerogels including, but
not
limited to, liquid-phase and vapor-phase crosslinked aerogels, fiber
reinforced
aerogels and reduced bonded aerogels. In these examples, the aerogel
insulation
layer is relatively more pliable and better conforms to sharp corners and
bends, and
is further assisted with conforming by the pliable substrate film.
This overview is intended to provide an overview of subject matter of the
present patent application. It is not intended to provide an exclusive or
exhaustive
explanation of the disclosure. The detailed description is included to provide
further
information about the present patent application.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, which are not necessarily drawn to scale, like numerals may
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describe similar components in different views. Like numerals having different
letter suffixes may represent different instances of similar components. The
drawings illustrate generally, by way of example, but not by way of
limitation,
various embodiments discussed in the present document.
Figure 1 is a perspective view of a building enveloped with one example of
a
thermal insulating construction wrap.
Figure 2 is a perspective view of a roll of the thermal insulating
construction
wrap of Figure 1.
Figure 3 is a schematic view of a wall with another example of the
thermal
insulating construction wrap installed thereon.
Figure 4A is a cross sectional view of a first example of a thermal
insulating
construction wrap.
Figure 4B is a cross sectional view of a second example of a thermal
insulating
construction wrap.
Figure 4C is a cross sectional view of a third example of a thermal
insulating
construction wrap.
Figure 4D is a cross sectional view of a fourth example of a thermal
insulating
construction wrap.
Figure 4E is a cross sectional view of a fifth example of a thermal
insulating
construction wrap.
Figure 4F is a cross sectional view of a sixth example of a thermal
insulating
construction wrap.
Figure 4G is a cross sectional view of a seventh example of a thermal
insulating
construction wrap.
Figure 5 is a schematic diagram showing one example of a production
assembly for a thermal insulating construction wrap.
Figure 6 is a block diagram showing one example of a method for
making a
thermal insulating construction wrap.
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DETAILED DESCRIPTION
Figure 1 is a perspective view of a building 100 enveloped with one example
of a thermal insulating construction wrap 110. The thermal insulating
construction
wrap 110 insulates the building 100 (e.g., single family residential homes,
multi-
family residential units, municipal buildings, office buildings, or the like)
from the
surrounding environment (e.g., the elements of nature including but not
limited to,
moisture, heat, cold or the like). For example, the thermal insulating
construction
wrap 110 thermally insulates the building 100 from the environment, and
increases
the overall R-value (e.g., thermal resistance) of the building 100. In some
examples,
the thermal insulating construction wrap 110 is used in combination with
additional
insulation techniques (e.g., fiberglass insulation, spray foam insulation,
foam board
insulation, or the like) to enhance the environmental isolation of the
building 100
relative to the surrounding environment, including enhancing the benefit of
other
types of insulation. Further, and as described in greater detail herein, the
thermal
insulating construction wrap 110 helps resist the infiltration of moisture
(e.g., liquid
water or humidity) into the building 100.
In an example, the thermal insulating construction wrap 110 is coupled to
the building 100 (e.g., installed over, around or the like). The thermal
insulating
construction wrap 110 is coupled to an exterior surface of the building 100,
including, but not limited to, wall panels, roof panels of the building 100 or
the like.
The thermal insulating construction wrap 110 pliably conforms to (e.g., comply
with
the contours) of the building 100. For example, the thermal insulating
construction
wrap 110 is adapted to pliably conform to corners, bends, fenestration
openings
(e.g., proximate windows and doors of the building 100) while maintaining the
insulation performance (and moisture resistance) of the thermal insulating
construction wrap 110.
Figure 2 is a perspective view of a roll 200 of the thermal insulating
construction wrap 110 of Figure 1. In the example shown, thermal insulating
wrap
110 includes liquid diversion features 210. The liquid diversion features 210
divert
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liquids along thermal insulating wrap 110 and divert liquids away from the
building
100 (shown in Figure 1), for instance toward the exterior of the building
while
minimizing penetration to the walls and building interior. The water diversion
features 210 include, but are not limited to, ridges; recesses; knurling;
raised
stippling; grooves; discontinuous ridges, recesses, grooves or the like
provided on
thermal insulating wrap 110. Liquid that penetrates a building exterior facia
(e.g.,
stucco, shingles, siding, brick, pre-fabricated panels or the like) flows
along the
water diversion features 210and is diverted away from the building 100. As
shown
in Figure 2, in an example, the water diversion features 210 extend along a
length of
thermal insulating wrap 110. In some examples, the water diversion features
210
extend at an angle (e.g., are perpendicular, orthogonal, angled or the like)
with
respect to, the length of thermal insulating wrap 110. In still other
examples, the
water diversion features are arranged in one or more patterns including, but
not
limited to, lines, undulating lines (e.g., waves), herringbone patterns, or
the like.
Optionally, the water diversion features 210 are constructed with, but not
limited to,
polymers, rubber or the like and coupled with the thermal construction wrap
110. In
other examples, the water diversion features 210 are formed with the thermal
construction wrap 110, and are integral to one or more of the layers.
Figure 3 is a schematic view of a wall panel 300 with another example of the
thermal insulating wrap 110 installed thereon. The thermal insulating wrap 110
includes a pliable substrate film 310 and an insulating layer 320, for
instance an
aerogel insulating layer 320. The aerogel insulating layer 320 is coupled to
(e.g.,
bonded to, adhered or the like) the pliable substrate film 310, and the
pliable
substrate film 310 facilitates the pliable conformity of thermal insulating
wrap 110.
In some examples, the aerogel insulating layer 320 is relatively brittle and
fractures
when deformed (e.g., rolled, bent, creased, or the like). The pliable
substrate film
310 localizes fracturing of the aerogel insulating layer 320, and thereby
improves
the performance (e.g., thermal insulation characteristics) of thermal
insulating wrap
110 by maintaining the integrity of the aerogel insulating layer 320. For
instance,
the aerogel insulating layer 320, even when fractured, maintains its location
along
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the pliable substrate firm 310 without falling away from thermal insulating
wrap
110, shedding or the like.
As described herein, thermal insulating wrap 110 is coupled to the building
100. For example, and as shown in Figure 3, thermal insulating wrap 110 is
coupled
to the wall panel 300 that is included in the building 100 (shown in Figure
1). The
wall panel 300 is coupled with a framing member 330 (e.g., a wall stud, a roof
truss,
or the like) of the building 100. The wall panel 300 includes a panel exterior
surface
340 that faces the surrounding (e.g., outdoor) environment. The coupling of
thermal
insulating wrap 110 to the wall panel 300 protects the panel exterior surface
340
from the surrounding environment. The aerogel insulating layer 320 is, in an
example, provided on an interior face of the pliable substrate film 310.
Accordingly,
when thermal insulating wrap 110 is coupled to the wall panel 300, the aerogel
insulating layer 320 is interposed between (e.g., positioned or sandwiched
between)
at least one pliable substrate film 310 and the panel exterior surface 340.
The
coupling of thermal insulating wrap 110 to the wall panel 300 insulates and
protects
the wall panel 300, and a building (for instance, the building 100 shown in
Figure
1), from the surrounding environment by providing the aerogel insulating layer
320
and the pliable substrate film 310.
A variety of materials for both the aerogel insulating layer 320 and the
pliable substrate film 310 are used in the various examples of the thermal
insulating
construction wrap 110. For instance, the pliable substrate film 310 includes
one or
more materials, such as polymers. In some examples, the pliable substrate film
310
includes, but is not limited to, one or more of thermoplastic polyolefins;
single
layer, non-woven, laminate or woven polypropylene; high density polyethylene
(HDPE) (e.g., spunbond HDPE); micro-perforated, cross-lapped films; films
laminated to spunbond nonwovens; films laminated or coated to polypropylene
wovens; supercalendered, wetlaid polyethylene fibril nonwoven (e.g., Tyvek, a
registered trademark of E.I. DuPont de Nemours and Co. of Wilmington,
Delaware); reflective aluminum foil; cross-linked polymer films and a layer of
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rubberized asphalt; composites of polymers; recycled materials; and composites
including laminates of the same.
In other examples, the aerogel insulating layer 320 includes, but is not
limited to, one or more of crosslinked aerogels such as wet silica gel soaked
in
solutions such as a diisocyanates that are heated to bond the diisocyanates;
polyisocyanates; epoxides; polystyrene or the like. Optionally, amine
functional
groups are used to bond polymers to the gel. For instance, 3-
aminopropyltriethoxysilane (APTES) is added to the gel as it sets. APTES
places
amine functional groups (-NH2) over the surface of the gel in addition to
hydroxyl
groups. These amine groups are used to bond a variety of polymers to the
framework of the aerogel insulating layer 320. For instance, the amine or
other
groups are used as an intermediate or adhesive layer to couple the aerogel
insulating
layer 320 with the pliable substrate wrap 310. In still other examples,
polymer
based aerogels are themselves cross linked (e.g., like braces) to enhance the
strength
of the aerogel insulating layer 320.
In still other examples, organic or inorganic materials such as microfibers,
filaments, fibers, or the like are added to the aerogel insulating layer 320
to
reinforce the aerogel (e.g., including enhancements to pliability and
increased
resistance to fracture). For instance, Nylon, glass fibers or the like are
used as a
substrate that receives the aerogel thereon before drying. In one example, the
aerogel (such as a silica aerogel) is applied to a fibrous batting (a porous,
flexible
fiber mat). The liquid of the composite aerogel insulating layer is
supercritically
dried to produce reinforced aerogels. For instance, the liquid of the layer
320 is
supercritically cooled (e.g., freeze dried) at low temperatures and low
pressures
relative to a liquid and gas transition curve of the aerogel liquid to avoid
the liquid-
gas boundary of the aerogel (and potential damage caused by surface tension).
In
another example, the aerogel liquid of the aerogel insulating layer is
supercritically
heated (e.g., dried by heat) at high temperature and high pressure relative to
the
liquid and gas transition curve of the aerogel liquid.
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In still other examples, polymers are added to aerogels to reinforce the
aerogel insulating layer 320 (e.g., polymer reinforced silica aerogels). For
instance,
vapor deposition along aerogels provides enhanced strength including
resistance to
fracture, increased pliability or the like. For instance, an existing aerogel
(dried) is
treated with a polymer coating that infiltrates the pores of the aerogel. One
or more
of chemical vapor deposition (CVD) or atomic layer deposition (ALD) are used
to
apply a polymer coating, such as methyl cyanoacrylate, to the aerogel.
Optionally, the bonding between atoms of the aerogel are limited to enhance
the aerogel flexibility (including pliability and correspondingly resistance
to
fracture). In some examples, a silica aerogel includes four-way bonds with
other
silicon atoms with intervening oxygen bridges. In other examples, bonding is
limited to, for instance a three-way bond between adjacent silicon atoms with
intervening oxygen bridges. The remaining fourth bond is instead bonded with a
methyl group or other group but does not otherwise connect to other silicon
atoms.
The reduced bonding increases the flexibility of the aerogel insulating layer
320 and
enhances its pliability to a degree closer to the pliable substrate film 310.
Accordingly, the resilience and performance of thermal insulating wrap 110 is
improved because the aerogel insulating layer 320 is adapted to withstand the
stress
and strain associated with coupling thermal insulating wrap 110 to the
building 100
(shown in Figure 1) including pliably deforming the wrap around corners,
through
openings or the like, relative to materials that are more prone to fracture
(e.g., are
brittle).
Further, methyl groups enhance the hydrophobicity (e.g., the ability to repel
a liquid, such as water) of the aerogel insulating layer 320. In an example,
the
hydrophobic and flexible aerogel insulating layer 320 cooperates with the
pliable
substrate film 310 to increase the overall moisture resistance of the thermal
insulating wrap 110.
Figure 4A is a cross sectional view of a first example of a thermal insulating
construction wrap 110. Thermal insulating wrap 110 includes the pliable
substrate
film 310 and the aerogel insulating layer 320. The pliable substrate film 310
includes
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an interior face 401 (e.g., a first side) and an exterior face 402 (e.g., a
second side).
The pliable substrate film 310 is coupled to the aerogel insulating layer 320.
For
example, the interior face 401 of the pliable substrate film 310 is coupled to
a first
side 403 of the aerogel insulating layer 320, and a second side 404 of the
aerogel
insulating layer 320 is adapted to couple with a building (such as the
building 100,
shown in Figure 1). In some examples, the coupling of the pliable substrate
film 310
with the aerogel insulating layer 320 includes infiltration of the aerogel
insulating
layer 320, such as by melting into pores of the aerogel insulating layer 320.
In other
examples, coupling of the pliable substrate film 310 with the aerogel
insulating layer
320 includes bonding of the film 310 to the aerogel insulating layer 320
(e.g., through
adhesives, welds, bonding between the aerogel and film molecules or the like,
for
instance through heating).
Figure 4B is a cross sectional view of a second example of a thermal
insulating construction wrap 110. The thermal insulating wrap 110 includes the
pliable substrate film 310 coupled to the aerogel insulating layer 320. In an
example, a first pliable substrate film 310A is coupled to a first side of the
aerogel
insulating layer 320. A second pliable substrate film 310B is coupled to a
second
side of the aerogel insulating layer 320. Coupling the pliable substrate film
310
(including component films 310A, B) to two or more sides (including edges) of
the
aerogel insulating layer 320 isolates the aerogel insulating layer 320 and
thereby
provides additional protection to the aerogel, while also increasing moisture
resistance for the thermal insulating construction wrap 110.
Additionally, coupling the pliable substrate film 310 to both sides of the
aerogel insulating layer 320 simplifies installation of thermal insulating
wrap 110 by
allowing for installation of the thermal insulating wrap 110 in more than one
orientation. For example, either of the first pliable substrate film 310A or
the second
substrate film 310B are applied to the exposed panel surface 340 while the
other of
the films 310B, A is exterior facing and provides moisture resistance. In this
example, the installer does not need to check the installation of the film to
ensure
the aerogel insulating layer 320 is interior relative to an exterior pliable
substrate
CA 3004021 2018-05-04
film because the thermal insulating construction wrap 110 in this example is
reversible.
Figure 4C is a cross sectional view of a third example of a thermal insulating
construction wrap 110. In the example shown, the thermal insulating wrap 110
includes an adhesive layer 405. Optionally, the adhesive layer 405 enhances
the
coupling between the pliable substrate film 310 and the aerogel insulating
layer 320,
and thereby minimizes decoupling of the layers (e.g., separation or
delamination).
In an example, the adhesive layer 405 is provided between the pliable
substrate film 310 and the aerogel insulating layer 320. In another example,
the
adhesive layer includes one or more component adhesive layers. For instance, a
first adhesive layer 405A is coupled with the pliable substrate film 310 and a
second
adhesive layer 405B is coupled with the aerogel insulating layer 320. The
first
adhesive layer 405A is bonded with the second adhesive layer 405B. For
instance, a
single adhesive layer 405 or multiple layers 405A, B are used in some examples
to
provide a bonding interface between the pliable substrate film 310 and the
aerogel
insulating layer 320 when the film and layer 320 do not readily bond.
In yet another example, the first adhesive layer 405A includes a first
adhesive material and the second adhesive layer 405B includes a second
adhesive
material. Optionally, the first adhesive material has increased bonding
strength with
the pliable substrate film 310 (e.g., polymers), and the second adhesive
material has
improved bonding strength with the aerogel insulating layer 320 (e.g., such as
crosslinked aerogels). The first adhesive and the second adhesive help to bond
disparate materials together and thereby improves the coupling of the pliable
substrate film 310 with the aerogel insulating layer in contrast with using a
single
adhesive (e.g., only the first adhesive).
Figure 4D is a cross sectional view of a fourth example of a thermal
insulating construction wrap 110. In this example, the thermal insulating wrap
110
includes the first pliable substrate film 310A, the aerogel insulation layer
320, and
the second pliable substrate film 310B. Additionally, the thermal insulating
wrap
110 includes a first adhesive layer 405A positioned on a first side of the
aerogel
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insulation layer 320 and a second adhesive layer 405B coupled to a second side
of
the aerogel insulation layer 320. In a similar manner to the thermal
insulating
construction wrap 110 shown in Figure 4B, the insulating wrap 110 shown in
Figure
4D is reversible to facilitate installation.
Figure 4E is a cross sectional view of a fifth example of a thermal insulating
construction wrap 110. In this example, the aerogel insulating layer 320 is
optionally less flexible (e.g., less pliable or more brittle). The aerogel is
provided as
aerogel slats 410 (e.g., strips, ribbons or the like) and retained along an
interior face
401 of the pliable substrate film 310. Scoring, slits, gaps or the like
(collectively,
gaps) between the aerogel slats 410 facilitate the pliability of the wrap 110.
For
instance, the thermal insulating construction wrap 110 readily folds, creases,
complies or the like at the gaps to ensure compliant application to the
contours of a
building. Optionally, the aerogel slats 410 are coupled with an intermediate
film,
substrate or adhesive (a base layer for the aerogel insulating layer 320) that
prearranges the slats with specified gaps, and the intermediate film of the
layer 320
is bonded with the pliable substrate film 310.
Figure 4F is a cross sectional view of a sixth example of a thermal insulating
construction wrap 110. In this example, the pliable substrate film 310, the
aerogel
insulating layer 320, or a combination thereof are included in a storage
membrane
420 that includes a plurality of storage cells 430. The aerogel insulating
layer 320
includes one or more of aerogel slats 410, aerogel filler or the like
positioned within
the storage cells 430. Optionally the aerogel insulating layer 320, coupled
with the
pliable substrate film 310 through the storage cells 430, is bonded with the
storage
membrane 420 (film 310), for instance with adhesives. In other examples, the
aerogel insulating layer 320 is retained in the cells 430 and not otherwise
bonded
with the film 310. The gaps between the aerogel (e.g., edges of the storage
cells
430) are relatively flexible and increase the pliability of the thermal
insulating
construction wrap 110 compared to sheets or boards of a base aerogel. During
assembly, the aerogel slats 410 (or filler) are nested between layers of film
(of the
aerogel insulating layer 320, the pliable substrate film 310, or both) and a
heat
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sealer, ultrasonic sealer, adhesive, or the like couples the layered film to
create a
film joint 440, while also forming the storage cells 430 with the aerogel
therein.
Figure 4G is a cross sectional view of a seventh example of a thermal
insulating construction wrap 110. The thermal insulating wrap 110 includes an
enclosure film 450 bonded to the pliable substrate film 310. The enclosure
film 450
includes a polymer material. The enclosure film 450 is a storage membrane 420
that
contains (e.g., holds or stores) one or more of aerogel slats 410, aerogel
filler or the
like positioned within the storage cells 430. The bonding of the enclosure
film 450
to the pliable substrate film 310 forms the plurality of storage cells 430
that are
adapted to enclose the aerogel insulating layer 320.
Figure 5 is a schematic diagram showing one example of a production
assembly 500 to assemble the thermal insulating construction wrap 110,
including
the various examples of the wrap described herein. The production assembly 500
includes a pliable substrate film spool 510 that includes the pliable
substrate film
310 and includes an aerogel insulating layer spool 520 that includes the
aerogel
insulating layer 320. The aerogel insulating layer 320 is pliable in one
example and
adapted to be drawn or otherwise conveyed through the production assembly 500.
In other examples, the aerogel insulating layer 320 is less pliable, and is
fed in
sheets, slats or the like into the assembly 500 (e.g., from a magazine, hopper
or the
like).
In this example, the production assembly 500 includes film guide rollers
530 adapted to support or position the pliable substrate film 310.
Additionally, the
production assembly 500 includes layer guide rollers 540 adapted to support or
position the aerogel insulating layer 320.
In an example, after processing with the production assembly 500, the
thermal insulating construction wrap 110 is rolled onto a thermal insulating
construction wrap spool 550 for transportation, storage, and installation. In
some
examples, the aerogel slats 410 (shown in Figures 4E-G) facilitate
conformation of
the thermal insulating wrap 110 to the thermal insulating construction wrap
spool
550. Additionally, in an example, the storage cells 430 and the intervening
gaps
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between slats, filler or the like facilitate conformation of the thermal
insulating wrap
110 to the thermal insulating construction wrap spool 550.
In some examples, the production assembly 500 includes an adhesive
applicator 560 positioned within the production assembly 500 that is adapted
to
apply an adhesive (e.g., the adhesive layer 405 of Figures 4C and 4D) to one
or
more of the pliable substrate film 310 or the aerogel insulating layer 320.
The
adhesive applicator 560 is positioned proximate one or more of the pliable
substrate
film 310 or the aerogel insulating layer 320 and dispenses the adhesive,
bonding
agent or the like to the pliable substrate film 310 or the aerogel insulating
layer 320.
In some instances, the production assembly 500 includes a heating element
570. The heating element 570 operates through one or more of radiative,
conductive, or convective modes of heat transfer and heats one or more of the
pliable substrate film 310 or the aerogel insulating layer 320. In one
example,
heating of the pliable substrate film 310 or the aerogel insulating layer 320
enhances
the bonding between the pliable substrate film 310 and the aerogel insulating
layer
320. Optionally, the heating element 570 heats the pliable substrate film 310
or the
aerogel insulating layer 320 before the pliable substrate film 310 is bonded
with the
aerogel insulating layer 320
In the example production assembly 500 shown in Figure 5, the assembly
includes a compression mechanism, such as a compression roller array 580 that
provides a compressive nip 585. The pliable substrate film 310 and the aerogel
insulating layer 320 are rolled between (e.g., fed into) the compressive nip
585 and
the compression roller array compresses (e.g., apply a force to both) the
pliable
substrate film 310 and the aerogel insulating layer 320 between opposed
compressive rollers. In other example, the compression mechanism includes
opposed compression plates configured to compress the film 310 and the aerogel
insulating layer 320 therebetween (e.g., where the thermal insulating
construction
wrap 110 is assembled in lineal sheets).
As described herein, and in some examples, the pliable substrate film 310
infiltrates the aerogel insulating layer 320 (e.g., the pores of the aerogel
insulating
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layer 320). In an example, the compression roller array 580 includes one or
more
heating elements that are included in individual rollers of the compression
roller
array 580. The heated rollers heat one or more of the pliable substrate film
310 or
the aerogel insulating layer 320 during the bonding process to help facilitate
bonding of the pliable substrate film 310 with the aerogel insulating layer
320. In
some instances, the heated rollers facilitate the bonding by activating the
adhesive
405. In other examples, the heated rollers heat the pliable substrate film 310
to a
melting temperature (or glass transition temperature), and the pliable
substrate film
310 infiltrates into the pores of the aerogel insulating layer 320 upon
compression at
the compressive nip 585 between the rollers.
In an example, the production assembly includes a drying system 590
adapted to help finish the bonding of the pliable substrate film 310 with the
aerogel
insulating layer 320. The drying system 590 is adapted to administer heated or
cooled air to the thermal insulating wrap 110. In some examples, the drying
system
590 is controlled and varies the temperature applied to the thermal insulating
wrap
110. Variation in drying (e.g., controlled cooling, staged cooling, staged
heating or
the like) tempers the thermal insulating wrap 110 and minimizes setting of
either or
both of the film 310 or the aerogel insulating layer 320 to facilitate winding
around
the thermal insulating construction wrap spool 550
Figure 6 shows one example of a method 600 for making thermal insulating
construction wrap including one or more of the thermal insulating construction
wrap
examples described herein. In describing the method 600, reference is made to
one
or more components, features, functions or steps previously described herein.
Where convenient, reference is made to the components, features, steps or the
like
with reference numerals. The reference numerals provided are exemplary and are
not exclusive. For instance, components, features, functions, steps or the
like
described in the method 600 include, but are not limited to, the corresponding
numbered elements provided herein and other corresponding elements described
herein (both numbered and unnumbered) as well as their equivalents.
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At 602, a pliable substrate film 310 is layered with an aerogel insulating
layer 320. In an example, layering the pliable substrate film 310 with the
aerogel
insulating layer 320 includes layering the pliable substrate film 310 with a
plurality
of aerogel slats 410. In another example, layering the pliable substrate film
310 with
the aerogel insulating layer 320 includes layering the pliable substrate film
310 with
the aerogel insulating layer 320 including a storage membrane 420 having
aerogel
filler in a plurality of storage cells 430.
In yet another example, the pliable substrate film 310 includes an exterior
substrate film and an interior substrate film (e.g., component films), and
layering the
pliable substrate film 310 with the aerogel insulating layer 320 includes
layering the
exterior substrate film with the aerogel insulating layer 320. Additionally,
layering
the pliable substrate film with the aerogel insulating layer includes layering
the
interior substrate film with the aerogel insulating layer 320, and the aerogel
insulating layer 320 is between the exterior and interior substrate films.
At 604, the pliable substrate film 310 is bonded with the aerogel insulating
layer 320. At 606, bonding includes feeding the layered pliable substrate film
310
and aerogel insulating layer 320 toward a compressive nip 585. At 608, bonding
includes compressing the layered pliable substrate film 310 and aerogel
insulating
layer 320 together with the compressive nip 585 (e.g., with a compression
mechanism including, but not limited to, compressive rollers, plates or the
like).
In one example, the pliable substrate film 310 and the aerogel insulating
layer 320 are laminated. Optionally, the pliable substrate film 310 is heated
(e.g., to
its melting point or glass transition temperature) and then laminated to the
aerogel
insulating layer 320. With pressure, for instance with the compressive nip 585
(e.g.,
rollers, plates or the like), the pliable substrate film 310 infiltrates pores
of the
aerogel insulating layer 320 to bond the film with the aerogel insulating
layer 320.
In still other examples, the aerogel insulating layer 320 is heated and the
pliable
substrate film 310 approaches its glass transition temperature when contacted
to the
heated aerogel insulating layer 320 (e.g., with the compressive nip 585).
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In another example, the aerogel insulating layer 320 includes aerogel slats
410. Optionally, the layered pliable substrate film 310 and aerogel insulating
layer
320 are compressed together (see the thermal insulation wrap 110 in Figure
4E). In
another option, compressing the pliable substrate film 310 and aerogel
insulating
layer 320 includes compressing exterior and interior substrate films together
with
the aerogel slats 410 therebetween (see Figures 4F, G). Additionally, bonding
the
pliable substrate film 310 with the aerogel insulating layer 320 and
compressing the
layered pliable substrate film 310 and aerogel insulating layer 320 includes
forming
storage cells 430 with the exterior and interior substrate films, and the
aerogel slats
410 are within the storage cells 430.
In still other examples, the pliable substrate film 310 and the aerogel
insulating layer 320 are coupled with an intermediate layer including, but not
limited to, one or more of, an adhesive (e.g., the adhesive 405 of Figures 4C
and
4D), a film configured to bond with each of the pliable substrate film 310 and
the
aerogel insulating layer 320 (e.g., where the film and layer do not readily
bond with
each other) or the like.
The pliable substrate film 310 and the aerogel insulating layer 320 are
optionally wound onto a spool, provided in lineal sheets or the like for
shipping,
storage and installation. Optionally, the film 310 and the aerogel insulating
layer
320 are fully bonded when wound onto the spool or stored in lineal sheets.
Various Notes & Examples
Example 1 includes subject matter such as a thermal insulating construction
wrap comprising: a pliable substrate film, the pliable substrate film is
resistant to at
least water penetration, and the pliable substrate film includes: an exterior
face, and
an interior face; an aerogel insulating layer coupled along the interior face
of the
pliable substrate film; and wherein the thermal insulating construction wrap
is
pliable.
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Example 2 can include, or can optionally be combined with the subject
matter of Example 1, to optionally include an adhesive layer interposed
between the
interior face and the aerogel insulating layer.
Example 3 can include, or can optionally be combined with the subject
matter of one or any combination of Examples 1 or 2 to optionally include
wherein
the pliable substrate film infiltrates the aerogel insulating layer to couple
the aerogel
insulating layer with the pliable substrate film.
Example 4 can include, or can optionally be combined with the subject
matter of one or any combination of Examples 1-3 to optionally include wherein
the
pliable substrate film infiltrates pores of the aerogel insulating layer.
Example 5 can include, or can optionally be combined with the subject
matter of one or any combination of Examples 1-4 to optionally include wherein
the
aerogel insulating layer includes a plurality of aerogel slats, and the
plurality of
aerogel slats are coupled along the interior face of the pliable substrate
film with one
or more of scoring or slits between each of the aerogel slats.
Example 6 can include, or can optionally be combined with the subject
matter of Examples 1-5 to optionally include wherein the aerogel insulating
layer
includes: a storage membrane including a plurality of storage cells, the
storage
membrane coupled along the interior face of the pliable substrate film, and
aerogel
filler within the storage cells of the plurality of storage cells.
Example 7 can include, or can optionally be combined with the subject
matter of Examples 1-6 to optionally include wherein the pliable substrate
film
includes: a storage membrane including a plurality of storage cells between
the
exterior and interior faces, and the aerogel insulating layer includes aerogel
filler
within the storage cells of the plurality of storage cells.
Example 8 can include, or can optionally be combined with the subject
matter of Examples 1-7 to optionally include wherein the pliable substrate
film
includes one or more of thermoplastic polyolefin, laminate of woven
polypropylene,
high density polyethylene (HDPE), spunbond HDPE, micro-perforated and cross-
lapped films, films laminated to spunbond nonwovens, films laminated or coated
to
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polypropylene wovens, supercalendered wetlaid polyethylene fibril nonwoven,
reflective aluminum foil, cross-linked polymer films, a layer of rubberized
asphalt,
or composites of polymers and recycled materials.
Example 9 can include, or can optionally be combined with the subject
matter of Examples 1-8 to optionally include wherein the aerogel insulating
layer
includes one or more of crosslinked aerogel, fiber-reinforced aerogel, vapor
deposition reinforced aerogel, polyimide aerogel or aerogel slats.
Example 10 can include, or can optionally be combined with the subject
matter of Examples 1-9 to optionally include wherein the pliable substrate
film is
impermeable to at least water.
Example 11 can include, or can optionally be combined with the subject
matter of Examples 1-10 to optionally include a method of making a thermal
insulating construction wrap comprising: layering a pliable substrate film
with an
aerogel insulating layer, the pliable substrate film is resistant to at least
water; and
bonding the pliable substrate film with the aerogel insulating layer, bonding
comprising: feeding the layered pliable substrate film and aerogel insulating
layer
toward a compressive nip, and compressing the layered pliable substrate film
and
aerogel insulating layer together with the compressive nip.
Example 12 can include, or can optionally be combined with the subject
matter of Examples 1-11 to optionally include heating one or more of the
pliable
substrate film or the aerogel insulating layer.
Example 13 can include, or can optionally be combined with the subject
matter of Examples 1-12 to optionally include wherein heating is before
bonding.
Example 14 can include, or can optionally be combined with the subject
matter of Examples 1-13 to optionally include wherein heating is during
bonding.
Example 15 can include, or can optionally be combined with the subject
matter of Examples 1-14 to optionally include wherein compressing the layered
pliable substrate film and aerogel insulating layer together includes
infiltrating the
aerogel insulating layer with the pliable substrate film.
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Example 16 can include, or can optionally be combined with the subject
matter of Examples 1-15 to optionally include wherein compressing the layered
pliable substrate film and aerogel insulating layer together includes rolling
the
layered pliable substrate and aerogel insulating layer between opposed
compressive
rollers having the compressive nip.
Example 17 can include, or can optionally be combined with the subject
matter of Examples 1-16 to optionally include applying an adhesive between the
pliable substrate film and the aerogel insulating layer.
Example 18 can include, or can optionally be combined with the subject
matter of Examples 1-17 to optionally include wherein layering the pliable
substrate
film with the aerogel insulating layer includes layering the pliable substrate
film
with a plurality of aerogel slats.
Example 19 can include, or can optionally be combined with the subject
matter of Examples 1-18 to optionally include wherein layering the pliable
substrate
film with the aerogel insulating layer includes layering the pliable substrate
film
with the aerogel insulating layer including a storage membrane having aerogel
filler
in a plurality of storage cells.
Example 20 can include, or can optionally be combined with the subject
matter of Examples 1-19 to optionally include wherein the pliable substrate
film
includes an exterior substrate film and an interior substrate film, and
layering the
pliable substrate film with the aerogel insulating layer includes: layering
exterior
substrate film with the aerogel insulating layer, and layering the interior
substrate
film with the aerogel insulating layer, the aerogel insulating layer between
the
exterior and interior substrate films.
Example 21 can include, or can optionally be combined with the subject
matter of Examples 1-20 to optionally include wherein the aerogel insulating
layer
includes aerogel slats, and compressing the layered pliable substrate film and
aerogel insulating layer together includes: compressing the exterior and
interior
substrate films together between the aerogel slats, and forming storage cells
with the
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exterior and interior substrate films, and the aerogel slats are within the
storage
cells.
Each of these non-limiting examples can stand on its own, or can be
combined in various permutations or combinations with one or more of the other
examples.
The above detailed description includes references to the accompanying
drawings, which form a part of the detailed description. The drawings show, by
way of illustration, specific embodiments in which the disclosure can be
practiced.
These embodiments are also referred to herein as "examples." Such examples can
include elements in addition to those shown or described. However, the present
inventors also contemplate examples in which only those elements shown or
described are provided. Moreover, the present inventors also contemplate
examples
using any combination or permutation of those elements shown or described (or
one
or more aspects thereof), either with respect to a particular example (or one
or more
aspects thereof), or with respect to other examples (or one or more aspects
thereof)
shown or described herein.
In the event of inconsistent usages between this document and any
documents so incorporated by reference, the usage in this document controls.
In this document, the terms "a" or "an" are used, as is common in patent
documents, to include one or more than one, independent of any other instances
or
usages of "at least one" or "one or more." In this document, the term "or" is
used to
refer to a nonexclusive or, such that "A or B" includes "A but not B," "B but
not
A," and "A and B," unless otherwise indicated. In this document, the terms
"including" and "in which" are used as the plain-English equivalents of the
respective terms "comprising" and "wherein." Also, in the following claims,
the
terms "including" and "comprising" are open-ended, that is, a system, device,
article, composition, formulation, or process that includes elements in
addition to
those listed after such a term in a claim are still deemed to fall within the
scope of
that claim. Moreover, in the following claims, the terms "first," "second,"
and
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CA 3004021 2018-05-04
"third," etc. are used merely as labels, and are not intended to impose
numerical
requirements on their objects.
The above description is intended to be illustrative, and not restrictive. For
example, the above-described examples (or one or more aspects thereof) may be
used in combination with each other. Other embodiments can be used, such as by
one of ordinary skill in the art upon reviewing the above description. The
Abstract
is provided to comply with 37 C.F.R. 1.72(b), to allow the reader to quickly
ascertain the nature of the technical disclosure. It is submitted with the
understanding that it will not be used to interpret or limit the scope or
meaning of
the claims. Also, in the above Detailed Description, various features may be
grouped together to streamline the disclosure. This should not be interpreted
as
intending that an unclaimed disclosed feature is essential to any claim.
Rather,
inventive subject matter may lie in less than all features of a particular
disclosed
embodiment. Thus, the following claims are hereby incorporated into the
Detailed
Description as examples or embodiments, with each claim standing on its own as
a
separate embodiment, and it is contemplated that such embodiments can be
combined with each other in various combinations or permutations. The scope of
the disclosure should be determined with reference to the appended claims,
along
with the full scope of equivalents to which such claims are entitled.
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